Gas heater / cooler apparatuses and methods

ABSTRACT

Gas heater/cooler apparatuses and methods of manufacturing thereof are provided. A gas heater/cooler apparatus has a gas pipe configured to transport a fluid inside a heat transfer block. A fluid flow through a cooling pipe in the proximity of the gas pipe or pushed towards the gas pipe by a fan cools the fluid. An electric heater disposed inside the heat transfer block close to the gas pipe may heat the fluid flowing therein via radiated heat.

BACKGROUND OF THE INVENTION

Embodiments of the subject matter disclosed herein generally relate toapparatuses and methods used in changing the temperature of fluidflowing through a pipe and, more particularly, to apparatuses andmethods in which either heating and/or cooling may be performed with thesame equipment.

The fossil fuels remain a main source of energy and, therefore, theinterest in developing new production fields has increased parallel withthe increase of demand. Since the availability of land-based productionfields is limited, tapping the vast amounts of offshore reserves hasbecome more imperative in spite of the technical challenges. Due to thelimited space on a rig, the offshore oil and gas exploration andexploitation needs more compact equipment than the conventionalland-based oil and gas equipment.

In conventional gas cooling equipment 1 as illustrated in FIG. 1, acontainer 10 houses a plurality of pipes 20 through which a coolingagent circulates. The cooling agent may be water. A fluid flow of oil orgas whose temperature is sought to be lowered is input through an inlet30, and output through an outlet 40. In its passage from the inlet 30 tothe outlet 40, the fluid flow surrounds the pipes 20. The cooling agentmay be input into the container 10 through a coolant inlet 50 in aninlet plenum 60, and then split to flow through the pipes 20 by a tubesheet 70. Similarly, after circulating through the pipes 20, the coolingagent may pass through an output tube sheet into an output plenum 80, tobe output via a coolant outlet 90. The output tube sheet is formed as asingle piece with the tube sheet 70.

In the gas cooling equipment 1, the input plenum 60 and the outputplenum 80 are located on the same side of the container 10, the pipes 20having a U-shape to extend along the container 10. The pipes 20 may besupported inside the container by baffles 95. The cooling agent istypically brought back to an initial temperature and re-circulated.

The pipes 20 being surrounded by the flow of gas or oil leads todegradation of the pipe walls making possible leaks there-through thatwould yield contamination of both the flow of gas or oil and the coolingagent.

In processing extracted fossil fuel, cooling or heating the flow of gasor oil may become necessary. Conventionally, the heating equipment isseparate from the cooling equipment. The presence of two separateequipments has the disadvantage of an increased cost and of an increasedspace requirement, which space may be scarce (e.g., on a rig operatingoffshore).

Additionally, the conventional use of two separate equipments limits thepossibility to promptly adjust the temperature of the gas or oil flow.

Accordingly, it would be desirable to provide apparatuses and methodsusable to either heat or cool a flow of gas or oil, thus, avoiding theafore-described problems and drawbacks.

BRIEF SUMMARY OF THE INVENTION

According to one exemplary embodiment, a gas heater/cooler apparatusincludes a heat transfer block, a gas pipe, a coolant pipe and anelectric heater. The gas pipe is configured to transport a fluid throughan inside of the heat transfer block. The coolant pipe is configured totransport coolant agent through the inside of the heat transfer block,the coolant pipe being located in the proximity of the gas pipe to coolthe fluid flowing therein via heat exchange with the cooling agentflowing through the coolant pipe. The electric heater is located insidethe heat transfer block close to the gas pipe to heat the fluid flowingtherein via radiated heat.

According to another exemplary embodiment, gas heater/cooler apparatusincludes a heat transfer block, a gas pipe, a fan and an electricheater. The gas pipe is configured to transport a fluid through aninside of the heat transfer block. The fan is configured to push a flowof air towards the gas pipe. The electric heater is located inside theheat transfer block close to the gas pipe to heat the fluid flowingtherein via radiated heat.

According to yet another exemplary embodiment, a method of manufacturinga gas heater/cooler apparatus is provided. The method includes mountinga gas pipe inside a heat transfer block configured to allow a coolantflow to pass there-through cooling a fluid flowing inside the gas pipe.The method further includes mounting an electric heater inside the heattransfer block and in the proximity of the gas pipe.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate one or more embodiments and,together with the description, explain these embodiments. In thedrawings:

FIG. 1 is a schematic diagram of a conventional gas cooling equipment;

FIG. 2 is a schematic diagram of a heater/cooler apparatus according toan embodiment;

FIG. 3 is a flow diagram of a method of manufacturing a heater/coolerapparatus according to an embodiment;

FIG. 4 is a schematic diagram of a heater/cooler apparatus according toanother embodiment;

FIG. 5 is a schematic diagram of a heater/cooler apparatus according toanother embodiment;

FIG. 6 is a schematic diagram of a heater/cooler apparatus according toanother embodiment; and

FIG. 7 is a schematic diagram of a heater/cooler apparatus according toanother embodiment.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS OF THE INVENTION

The following description of the exemplary embodiments refers to theaccompanying drawings. The same reference numbers in different drawingsidentify the same or similar elements. The following detaileddescription does not limit the invention. Instead, the scope of theinvention is defined by the appended claims. The following embodimentsare discussed, for simplicity, with regard to the terminology andstructure of a gas processing system. However, the embodiments to bediscussed next are not limited to these systems, but may be applied toother systems that require a reduced size equipment capable to both heator cool a fossil fuel (fluid) flow.

Reference throughout the specification to “one embodiment” or “anembodiment” means that a particular feature, structure, orcharacteristic described in connection with an embodiment is included inat least one embodiment of the subject matter disclosed. Thus, theappearance of the phrases “in one embodiment” or “in an embodiment” invarious places throughout the specification is not necessarily referringto the same embodiment. Further, the particular features, structures orcharacteristics may be combined in any suitable manner in one or moreembodiments.

As discussed above with regard to FIG. 1, the prior art equipment hasthe disadvantage of being bulky because separate pieces of equipment areused for heating and for cooling, respectively. Additionally, exposureof the pipes carrying the cooling agent to the fluid flow leads in timeto degradation of the pipes which may result in cross-contaminatingleaks.

According to one embodiment illustrated in FIG. 2, a gas heater/coolerapparatus 100 includes a heat transfer block 110 inside which there is apipe 120 carrying gas (or other fossil fuel, or fluid) whose temperatureis sought to be controlled. The pipe 120 has a shape designed toincrease exposure of a longer portion of the pipe 120 to temperaturechanging agents. For example, the pipe 120 may have a spiral shape (butits shape is not limited thereof). The pipe 120 is made, in anembodiment, from a material that is a good heat conductor, to spend asmall amount of energy and time in modifying the temperature of the pipe120 material. For example, the pipe 120 may be made of stainless steel.

A cooling agent is a fluid flow entering the heat transfer block 110 viaan inlet 130 and exiting the heat transfer block via an outlet 140. Theheating agent is an electric heater 150 located in the proximity of thepipe 120. Thus, the gas in the pipe 120 may be cooled by the fluid flowand/or may be heated due to heat radiated by the electric heater 150,while passing through the heat transfer block 110.

In another embodiment illustrated in FIG. 3, a method 200 ofmanufacturing a gas heater/cooler apparatus includes mounting a gas pipeinside a heat transfer block configured to allow a coolant flow to passthere-through, at S210. Further, the method 200 includes mounting anelectric heater inside the heat transfer block and in the proximity ofthe gas pipe, at S220.

The method 200 may also include mounting temperature sensors atdifferent locations along the gas pipe, and/or along the path of thecoolant flow. Temperature sensors may be located before and after anarea where heat exchange between gas in the gas pipe 120 and the fluidflow occurs, to measure a change of the temperature of the gas and achange of the temperature of the coolant.

The method 200 may further include mounting a fluid regulator on thepath of the coolant flow, the fluid regulator being configured to modifythe amount of coolant flow entering the heat transfer block. The fluidregulator may be connected to one or more temperature sensors configuredto measure a temperature of the coolant and/or of the gas exiting theheat transfer block, to enable the fluid regulator to adjust the amountof coolant flow based on the temperature information received from theone or more sensors.

The method 200 may also include mounting a power supply configured toprovide power to the electric heater and a switch configured to cut offthe power supply based on temperature information received from one ormore temperature sensors.

In another embodiment, the method 200 may include mounting the flowregulator, the power supply, the switch, and the one or more temperaturesensors, and, then, connecting these components to a controller. Thecontroller is configured to control the flow regulator and the powersupply to adjust the amount of coolant and the power supplied to theelectric heater based on the temperatures measured by the sensors, inorder to achieve a target output temperature of the gas in the gas pipe.

The method 200 may also include mounting alarms in the apparatus. Forexample, a cooling agent temperature alarm may be connected to a coolantoutput temperature sensor located and configured to measure an outputtemperature of the coolant flow. The cooling agent temperature alarm maybe configured to output an alarm signal when the output temperature hasa value outside a predetermined temperature range. In another example, aswitch may be connected to a coolant output temperature sensor locatedand configured to measure an output temperature of the fluid flowinginside the gas pipe. The switch may be interposed between the powersupply and the electric heater, and be configured to cut off the powerto the heater when the output temperature exceeds a predetermined value.

According to another exemplary embodiment, illustrated in FIG. 4, a gasheater/cooler apparatus 300 includes a heat transfer block 310 insidewhich a pipe 320 carrying gas whose temperature is sought to becontrolled is immerged. The heat transfer block may be made of a castedpiece of aluminum. The pipe 320 enters the heat transfer block 310 viaan inlet 322 and exits the heat transfer block 310 via an outlet 324.Close to the inlet 322, inside or outside the heat transfer block 310, afirst temperature sensor 326 may be located to measure the inputtemperature of the gas in the pipe 320. Close to the outlet 324, insideor outside the heat transfer block 310, a second temperature sensor 328may be located to measure the output temperature of the gas in the pipe320. For example, the input temperature of the gas in the pipe 320 maybe about 250° C., and the output temperature of the gas may be about150° C.

Another pipe 330, through which a cooling agent flows, is placed insidethe heat transfer block 310 in the proximity of the pipe 320. The pipe320 and the pipe 330 may have spiral shapes running substantiallyparallel to each other to maximize the heat exchange therebetween. Thecooling agent may be mineral oil. The pipe 330 enters the heat transferblock 310 via an inlet 332 and exits the heat transfer block 310 via anoutlet 334. Close to the inlet 332, a third temperature sensor 336 maybe located inside or outside the heat transfer block 310, to measure theinput temperature of the cooling agent in the pipe 330. Close to theoutlet 334, a fourth temperature sensor 338 may be located inside oroutside the heat transfer block 310, to measure the output temperatureof the cooling agent in the pipe 330. For example, the input temperatureof the cooling in the pipe 330 may be about 70° C., and the outputtemperature of the cooling agent may be about 75° C.

The heat transfer block may be made of a casted piece of aluminum oranother material or environment.

A gas temperature alarm 329 and/or a cooling agent temperature alarm 339may be associated with a respective temperature sensor located close tothe outlets. The alarms are configured to output alarm signals when theoutput temperature of the gas or of the cooling agent respectively has avalue outside a corresponding predetermined temperature interval orexceeds a corresponding upper or lower value. The alarm signal may be avisual or an audio indication or may trigger adjustment of the coolantflow and/or of the power supplied to the electric heater 340.

The pipes 320 and 330 are made, in an embodiment, from materials (or thesame material) that are good heat conductors, to spend a small amount ofenergy and time in modifying the temperature of the pipes 320 and 330.For example, the pipes 320 and 330 may be made of stainless steel.

An electric heater 340 is located also in the proximity of the pipe 320,according to an embodiment, in a manner in which to optimize a heattransfer towards the pipe 320 while minimizing a heat transfer towardsthe pipe 330. Thus, inside the heat transfer block 310 the gas, the gasin the pipe 320 may be cooled due to the cooling agent in the pipe 330having a lower temperature than the gas and/or may be heated due to heatradiated by the electric heater 340.

The gas heater/cooler apparatus 300 further includes a power supply 350that provides power to the electric heater 340 and a flow regulator 360located along a pipe through which the cooling agent enters the heattransfer block 310. The flow regulator 360 is configured to control theamount of cooling agent flowing along the pipe 330 inside the heattransfer block 310. The flow regulator may be an orifice in the coolantpipe wall, an area of the orifice being adjustable. For example, thecooling agent (mineral oil) flow may be about 28 l/min.

The temperature sensors 326, 328, 336, and 338, the power supply 350 andthe flow regulator 360 may be connected to a controller 370. Thecontroller 370 may send signals to the power supply 350 and to the flowregulator 360 based on the temperature values received from thetemperature sensors 326, 328, 336, and 338 in order to achieve atargeted temperature of the gas exiting the heat transfer block 310.

Another schematic diagram of a gas heater/cooler apparatus 380 isillustrated in FIG. 5. In addition to elements already describedrelative to FIG. 4, the gas heater/cooler apparatus 380 includes aswitch 382 interposed between the power supply 350 and the electricheater 340, the switch 382 being configured to cut off the power to theelectric heater. For example, the power may be cut-off (1) when theoutput temperature of the gas or the coolant exceeds a predeterminedvalue, (2) when a signal is received from an automatic controller or (3)when the switch is flipped between an open state and a close state by acommand received via an interface 384. The mineral oil flow may be 28l/min, the mineral oil temperature raising across the heater/coolerapparatus 380 from 70° C. to 75° C., and the gas flow may be 56 l/minthe gas temperature dropping across the heater/cooler apparatus 380 from250° C. to 150° C.

A layout of a heater/cooler apparatus 390 similar to the apparatuses 300and 380 described above is illustrated in FIG. 6. The heater/coolerapparatus 390 stands on a mounting foot 392. The electric heater 340 maybe lowered inside or raised outside the heat transfer block 310 using alifting mechanism 394. The apparatus operation information (includingtemperature information) may be transmitted via a module 396. The heattransfer block 310 may be surrounded by a thermal insulating layer orcasing 398. In FIG. 6, the gas pipe 320 and the coolant pipe 330 havehelix shapes arranged on the same axis and running substantiallyparallel to each other.

According to another exemplary embodiment, illustrated in FIG. 7, a gasheater/cooler apparatus 400 includes a heat transfer block 410 insidewhich there is a pipe 420 carrying gas whose temperature is sought to becontrolled. The pipe 420 enters the heat transfer block 410 via an inlet422 and exits the heat transfer block 410 via an outlet 424. The pipe420 is made, in an embodiment, from a material that is a good heatconductor, to spend a small amount of energy and time in modifying thetemperature of the pipe 420. For example, the pipe 420 may be made ofstainless steel. The pipe 420 may have spiral shape to maximize the heatexchange.

Close to the inlet 422, inside or outside the heat transfer block 410, afirst temperature sensor 426 may be located to measure the inputtemperature of the gas in the pipe 420. Close to the outlet 424, insideor outside the heat transfer block 410, a second temperature sensor 428may be located to measure the output temperature of the gas in the pipe420.

A fan 430 pushes an air flow through the heat transfer block 410 towardsthe pipe 420. Here, air is mentioned as cooling agent. However, othergas mixtures may be used, cooled and re-circulated through the heattransfer block 410. The advantage of using air, even ambient air, withtemperature between −40° C. to 50° C., is that, in this case, nore-circulating loop is necessary. The air flow pushed by the fan 430towards the pipe 420 may pass through permeable walls (e.g., walls withholes to allow the air to pass there-through) or may be channeledthrough openings in the walls.

An electric heater 440 is located also in the proximity of the pipe 420.Thus, inside the heat transfer block 410 the gas, the gas in the pipe420 may be cooled due to the air flow having a lower temperature thanthe gas and/or may be heated due to heat radiated by the electric heater440.

The gas heater/cooler apparatus 400 further includes a first powersupply 450 that provides power to the electric heater 440 and a secondpower supply 460 that provides power to the fan 430.

The temperature sensors 426, 428, and the power supplies 450 and 460 maybe connected to a controller 470. The controller 470 may send signals tothe power supplies 450 and 460 based on the temperature informationreceived from the temperature sensors 426, and 428 in order to achieve atargeted temperature of the gas exiting the heat transfer block 410.

The disclosed exemplary embodiments provide apparatuses and methods ofmanufacturing thereof in which apparatuses either heating and/or coolingof a fossil fuel (fluid) flow may be performed. It should be understoodthat this description is not intended to limit the invention. On thecontrary, the exemplary embodiments are intended to cover alternatives,modifications and equivalents, which are included in the spirit andscope of the invention as defined by the appended claims. Further, inthe detailed description of the exemplary embodiments, numerous specificdetails are set forth in order to provide a comprehensive understandingof the claimed invention. However, one skilled in the art wouldunderstand that various embodiments may be practiced without suchspecific details.

Although the features and elements of the present exemplary embodimentsare described in the embodiments in particular combinations, eachfeature or element can be used alone without the other features andelements of the embodiments or in various combinations with or withoutother features and elements disclosed herein.

This written description uses examples of the subject matter disclosedto enable any person skilled in the art to practice the same, includingmaking and using any devices or systems and performing any incorporatedmethods. The patentable scope of the subject matter is defined by theclaims, and may include other examples that occur to those skilled inthe art. Such other examples are intended to be within the scope of theclaims.

What is claimed is:
 1. A gas heater/cooler apparatus, comprising: a heattransfer block; a gas pipe configured to transport a fluid inside of theheat transfer block; a coolant pipe configured to transport a coolantagent inside of the heat transfer block, the coolant pipe being locatedin a proximity of the gas pipe to cool the fluid flowing therein viaheat exchange with the cooling agent flowing through the coolant pipe;and an electric heater located inside the heat transfer block close tothe gas pipe to heat the fluid flowing therein via radiated heat.
 2. Thegas heater/cooler apparatus of claim 1, further comprising at least oneof: a temperature sensor located close to where the gas pipe exits theheat transfer block and configured to measure an output temperature ofthe fluid, and a temperature sensor located close to where the coolantpipe exits the heat transfer block and configured to measure an outputtemperature of the coolant agent.
 3. The gas heater/cooler apparatus ofclaim 1, further comprising: one or more temperature sensors configuredto measure temperatures at different locations along the gas pipe and/orthe coolant pipe; and a temperature information acquisition andtransmission module configured to gather temperature information fromthe temperature sensors and transmit the gathered information.
 4. Thegas heater/cooler apparatus of claim 1, further comprising: atemperature sensor located close to where the coolant pipe exits theheat transfer block and configured to measure an output temperature ofthe coolant agent; and at least one of: a cooling agent temperaturealarm connected to the temperature sensor and configured to output analarm signal when the output temperature has a value outside apredetermined temperature range, and a coolant flow regulator connectedto the temperature sensor and configured to adjust an amount of coolantagent transported in time through the coolant pipe based on a currentvalue of the output temperature.
 5. The gas heater/cooler apparatus ofclaim 1, further comprising: a temperature sensor located close to wherethe gas pipe exits the heat transfer block and configured to measure anoutput temperature of the fluid; and a gas temperature alarm connectedto the temperature sensor and configured to output an alarm signal whenthe output temperature of the fluid has a value outside a predeterminedtemperature range.
 6. The gas heater/cooler apparatus of claim 1,further comprising: a temperature sensor located close to where the gaspipe exits the heat transfer block and configured to measure an outputtemperature of the fluid or close to where the coolant pipe exits theheat transfer block and configured to measure an output temperature ofthe coolant agent; a power supply configured to provide power to theelectric heater; and a switch connected to the temperature sensor andinterposed between the power supply and the electric heater, the switchbeing configured to cut off the power to the electric heater when theoutput temperature exceeds a predetermined value.
 7. The gasheater/cooler apparatus of claim 1, further comprising: one or moretemperature sensors configured to measure temperatures at differentlocations along the gas pipe and/or the coolant pipe; a coolant flowregulator configured to adjust an amount of coolant agent transported intime through the coolant pipe; a power supply configured to providepower to the electric heater; and a controller connected to temperaturesensors, the coolant flow regulator and the power supply, the controllerbeing configured to control the coolant flow regulator and the powersupply based on temperature information received from the temperaturesensors.
 8. The gas heater/cooler apparatus of claim 1, wherein the gaspipe and the coolant pipe have co-axial helix shapes inside the heattransfer block.
 9. A gas heater/cooler apparatus, comprising: a heattransfer block; a gas pipe configured to transport a fluid through aninside of the heat transfer block; a fan configured to push a flow ofair towards the gas pipe; and an electric heater disposed inside theheat transfer block close to the gas pipe to heat the-a fluid flowingtherein via radiated heat.
 10. A method of manufacturing a gasheater/cooler apparatus, the method comprising: mounting a gas pipeinside a heat transfer block configured to allow a coolant flow to passthere-through cooling a fluid flowing inside the gas pipe; and mountingan electric heater inside the heat transfer block and in a proximity ofthe gas pipe.
 11. The heater/cooler apparatus of claim 9, furthercomprising a temperature sensor located close to where the gas pipeexits the heat transfer block and configured to measure an outputtemperature of the fluid.
 12. The gas heater/cooler of claim 9, furthercomprising: one or more temperature sensors configured to measuretemperatures at different locations along the gas pipe; and atemperature information acquisition and transmission module configuredto gather temperature information from the temperature sensors andtransmit the gathered information.
 13. The gas heater/cooler of claim 9,further comprising at least one of: a cooling agent temperature alarmconnected to the temperature sensor and configured to output an alarmsignal when the output temperature has a value outside a predeterminedtemperature range, and a coolant flow regulator connected to thetemperature sensor and configured to adjust an amount of coolant agenttransported based on a current value of the output temperature.
 14. Thegas heater/cooler of claim 9, further comprising: a temperature sensorlocated close to where the gas pipe exits the heat transfer block andconfigured to measure an output temperature of the fluid; and a gastemperature alarm connected to the temperature sensor and configured tooutput an alarm signal when the output temperature of the fluid has avalue outside a predetermined temperature range.
 15. The gasheater/cooler of claim 9, further comprising: a temperature sensorlocated close to where the gas pipe exits the heat transfer block andconfigured to measure an output temperature of the fluid; a power supplyconfigured to provide power to the electric heater; and a switchconnected to the temperature sensor and interposed between the powersupply and the electric heater, the switch being configured to cut offthe power to the electric heater when the output temperature exceeds apredetermined value.
 16. The gas heater/cooler of claim 9, furthercomprising: one or more temperature sensors configured to measuretemperatures at different locations; a coolant flow regulator configuredto adjust an amount of coolant agent transported in time; a power supplyconfigured to provide power to the electric heater; and a controllerconnected to temperature sensors, the coolant flow regulator and thepower supply, the controller being configured to control the coolantflow regulator and the power supply based on temperature informationreceived from the temperature sensors.
 17. The gas heater/cooler ofclaim 9, wherein the gas pipe has co-axial helix shapes inside the heattransfer block.
 18. The method of claim 10, the method furthercomprising: mounting temperature sensors at different locations alongthe gas pipe or along the past of the coolant flow.
 19. The method ofclaim 10, the method further comprising: mounting a fluid regulator onthe path of the coolant flow, the fluid regulator being configured tomodify the amount of coolant flow entering the heat transfer block. 20.The method of claim 10, the method further comprising: mounting a powersupply configured to provide power to the electric heater and a switchconfigured to cut off the power supply based on temperature informationreceived from one or more temperature sensors.
 21. The method of claim10, the method further comprising: mounting the flow regulator, thepower supply, the switch, and the one or more temperature sensors, andconnecting these components to a controller.
 22. The method of claim 10,the method further comprising: mounting alarms in the gas heater/coolerapparatus.